Growth Manufacturers Case Study
- Atlantic Awning
- Operations
LEAN Innovation Program Increases Efficiencies and Employee Engagement
The Challenge
Another awning company in Ohio used Ohio MEP and recommended it. Misunderstood what MassMEP did. Had employee call MassMEP and ask for help in finding potential new hires. MassMEP Project Manager came to meet with them and responded that he couldn’t help with that, but he could help with a lot of other things. The proceeded to do a walked throughout the company and as they did so the MassMEP Project Manager indicated areas and the issues and that MassMEP could assist with. Atlantic Awning president Cheryl Yennaco knew her strengths were in being able to recognize what needs to be done. She also recognized that having assistance and direction in implementing solutions was required to optimize results for Atlantic Awning. Cheryl said “Let’s do it.”
The Solution
During the walk-through a Lean Innovation Program was identified that included: Value Stream Mapping, total shop kaizen, establishing a Kanban system, 5S of the office as well as the install trucks, visual scheduling, and shop layout changes. Training took place over a six-month period and resulted in improved overall efficiencies. For example, value stream mapping opened up the employees eyes to the entire process, and enabled them to understand their part in the process. Setting up the Kanban system helped them understand and improve their demand cycle and ordering process. Visual scheduling removed duplicate information from shop folders, enabled employees to understand work for the following day, and allowed for clearer communication to their customer without management intervention. Fabrication tables were revamped for cutting and stitching.
Cheryl remarked that in addition to the noted changes made, a big impact of the training was that everybody was included in the process. This resulted in all employees taking ownership of organizing the training and the outcomes. Employees really engaged in making changes in their workspace and how their space could be better. Though MassMEP was at Atlantic Awning for six months, changes continued to be made over a year. Overall the employees are happier, Kanbans continue to be maintained, and communication is improved through daily shop meetings and weekly production meetings.
The Results
$10,000-15,000
Invested to improve work stations
$45,000
In Training cost savings
50%
Increased Productivity in sewing
30%
Increased Productivity in Wrapping
We will bring MassMEP in again. They were fantastic and able to communicate with all personalities. They were available for questions even when not here on site.
About Atlantic Awning
A family-owned and operated business, Atlantic Awning creates custom awnings and enclosures for commercial locations and private residences in the Greater Boston and New Hampshire area. The company’s custom solutions provide shade and weather protection to our customers’ entrances, decks and outdoor living areas.
Established in 1888, Atlantic Awning is one of the area’s first awning companies to service the Boston area and today has installed more than 100,000 awnings in New England. As a provider of contemporary custom awning solutions, Atlantic Awning’s offerings now extend far beyond traditional fixed-frame awnings. Customers can select from their line of standing seam awnings, copper awnings, aluminum, retractable and many new styles of welded frames. Their product line includes walkway awnings, entrance awnings, canopies, door hoods, window awnings and aluminum structural roofs. Atlantic Awning’s commercial line also includes back-lit awnings and shade sails for both commercial and residential markets.